JP2010065522A - Solar battery tile - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a solar battery tile particularly used for converting solar energy into electric energy on a roof of a building, in the solar battery tile. <P>SOLUTION: This solar battery tile 10 includes a carrier tile 12 and a solar battery tile 14 supported in a recessed part 20 formed on the first side 18 of the carrier tile 12. Through-hole electric terminals 28 and 30 are arranged in the carrier tile 12, and these are electrically connected to the solar battery cell 14. A cover plate 16 overlaps with a surface of the solar battery cell 14, and is installed on the carrier tile 12 by sealing. The solar battery tile 10 is manufactured with an appearance similar to a slate or a shingle used for a covering of the roof. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to solar tiles, and in particular, but not limited to, solar tiles used to convert solar energy into electrical energy on a building roof.

  To supplement building energy needs, it is well known to use solar panels mounted on the roof of the building. Such panels can be adapted to roofs overlying existing roofing materials. That is, the panel itself does not replace or act as a roofing material.

  Applicants have previously devised a solar tile assembly that can act as a roofing material. The assembly includes: a base tile, through which one or more mechanical fasteners are used for securing to the underlying roof structure, and attached to the base tile; One or more solar cell cover tiles that overlap. Each cover tile is provided with one or more solar cells and converts solar energy into electrical energy. Cover tiles are mechanically and electrically coupled to corresponding base tiles by connecting posts. The post is pushed through a through hole formed in the base tile. The first end of each post extends over the base tile and is received in the through-hole electrical terminal of the cover tile to provide electrical and mechanical coupling of the cover tile to the base tile. The opposite second end of each post extends into a recess in the base tile and is received in a slot in an electrical connection tube that is next installed in the recess in the base tile. The electrical and mechanical connection of the second end of the post requires a combination of linear and rotational movement of the connecting tube.

Further details of Applicants' above solar cell tile assembly are provided in Singapore Patent Application No. 200716871-9.
The present invention is the result of further research and development related to the cover tile of the solar cell tile assembly.

  In the claims that follow and in the following description of the invention, the term “comprise” or eg “comprising” (“unless” is included) unless there is another requirement from the context for a particular language of expression or necessary implications. Variations such as “comprise”) ”or“ comprising ”are used in an inclusive sense, that is to say the presence of the stated property, but in various aspects of the invention It does not exclude the presence or addition of characteristics.

One aspect of the present invention is:
A carrier tile having a first side provided with a recess;
One or more solar cells installed in the recess; and a cover plate overlying the solar cells and hermetically attached to the carrier tile;
A solar cell tile is provided.
The carrier tile may be made from a plastic material.
Further, the carrier tile may be formed by a molding method.

In one embodiment, the solar tile has a slate-like appearance when viewed from the side where the solar cells are provided. In this embodiment, the carrier tile is of a slate-like color.
The solar cell may also be of a slate-like color, or alternatively it may be formed so that it is substantially transparent, in which case the underlying carrier tile can be seen through the solar cell .

In the first embodiment of the solar tile, the cover plate may overlap the carrier tile. Further, the cover plate may have substantially the same footprint as the carrier tile, so that the respective edges of the carrier tile and the cover plate are substantially common terminations. This provides a solar tile having a substantially flat top surface. In this embodiment, the combined thickness of the solar cells is substantially less than the depth of the recess.
In the second aspect of the solar cell tile, the cover plate may be installed in the recess. In this embodiment, the solar cell and the cover plate may be formed such that the combined thickness is substantially equal to the depth of the recess. This makes the top surface of the solar cell tile (which is the surface provided by the cover plate) substantially flat.

At least one edge of the solar tile may be provided with a curved or rounded profile.
One or more electrical terminals may be provided on the solar tile through which the electricity generated by the solar cells may flow to a distant electrical device, such as a storage battery, water heater, inverter or appliance. it can.
The solar tile can be perforated and contains a fastener for holding or securing the solar tile assembly to a desired location or position or support.

In one aspect, each electrical terminal may be located adjacent to the hole. In fact, each terminal may circumscribe its respective hole. In this embodiment, each electrical terminal is a through-hole terminal and may include a ring made of a conductive material.
A conductor is provided to establish an electrical connection between each electrical terminal and the solar cell. Each conductor may be in the form of a busbar. Each bus bar can be coupled to a corresponding electrical terminal. Electrical terminals and busbars may be molded into the carrier tile.

  In embodiments where the cover plate overlaps the carrier tile, the electrical terminals and / or conductors may be sandwiched between the carrier tile and the cover plate. However, in embodiments where the cover tile is installed in the recess, the electrical terminals and / or conductors may be embedded within the carrier tile.

A further aspect of the invention is:
A carrier tile with at least one through-hole electrical terminal;
One or more solar cells supported on a carrier tile; and a conductor for each electrical terminal;
Wherein each conductor provides an electrical connection between a respective electrical terminal and the solar cell; and at least a portion of the electrical terminal and the conductor is embedded in the solar tile. Including the solar cell tile.

  One aspect of the invention will now be described, by way of example, with reference to the accompanying drawings.

FIG. 1a shows a first embodiment of a solar cell tile according to the invention. FIG. 1b is an exploded view of the tile shown in FIG. 1a. FIG. 1c is a schematic view of a carrier tile incorporated into the solar cell tile shown in FIGS. 1a and 1b. Fig. 2a shows a second embodiment of a solar cell tile according to the present invention. FIG. 2b is an exploded view of the tile shown in FIG. 2a. FIG. 2c is a schematic illustration of a carrier tile incorporated in the solar cell tile shown in FIGS. 2a and 2b.

FIG. 3 shows a part of a roof covered with a plurality of solar cell tiles according to the invention. FIG. 4 is a cross-sectional view of a sealing system incorporating one embodiment of a solar cell tile. FIG. 5 is a cross-sectional view of a sealing system incorporating another aspect of a solar cell tile. FIG. 6a is an exploded view of a base tile capable of mounting multiple solar tiles, the base tile providing a series connection between three banks of parallel connected tiles.

6b is an equivalent circuit diagram of tiles connected by the base tile shown in FIG. 6a. FIG. 6c is an exploded view of a base tile on which multiple solar tiles can be mounted, the base tile being configured to connect each tile in series. FIG. 6d is an equivalent circuit diagram of tiles connected by the base tile shown in FIG. 6c. FIG. 7 is a schematic diagram of an electrical connection system that can be incorporated into a base tile to provide electrical connection between solar tiles. FIG. 8 shows the assembled base tile secured to the roof structure.

Detailed description accompanying FIG preferred embodiments, and and in particular to FIG. 1 a to 1 c, aspects of the photovoltaic tile 10 according to the present invention comprises a carrier tile 12 and solar cell 14. The carrier tile 12 has a first side 18 with a recess 20 provided thereon. The solar battery cell 14 has a relative dimension to the recess 20 so that the cell 14 is installed in the recess 20. Cover plate 16 overlies solar cells 14 and can be hermetically attached to carrier tile 12. In this particular embodiment, the cover plate 16 has substantially the same footprint as the carrier tile 12 and is juxtaposed with it, so that the edges of the plate 16 and the tile 12 have a common end.

  The front or exposed surface 22 of the solar cell tile 10 has a flat surface 24. Formation of the flat surface 24 is realized by forming the thickness of the solar battery cell 14 substantially equal to or less than the depth of the recess 20 and flattening the upper surface of the cover plate 16.

In order for a house or other building with solar tiles 10 to match the surrounding homes and buildings that would be provided with a slate or shingles roof, solar tiles 10 have a slate-like appearance, i.e. Can be made to have a slate-like color.
This can be accomplished by forming a slate-like colored carrier tile. Furthermore, the solar cells 14 can be made substantially transparent so that the slate-like color of the underlying carrier tile 12 can be seen through the solar cells 14; It may be formed in a slate-like color. The cover plate 16 is made of a transparent material to maximize the transmission of solar energy to the cell 14. This also makes the slate-like color of the underlying carrier tile 12 and / or solar cell 14 visible through the cover plate.

The edge of the cover plate 16 may be hermetically attached to the periphery of the carrier tile 12 using sealant, adhesive or ultrasonic welding.
The lower edge or strip 26 of the solar tile 10 consists of the lower edge of the cover plate 16, which is formed with a curved or round cross section. Thereby, it is considered that the reduction of the lifting pressure or the effect of the lifting pressure can be supported in a strong wind condition.
In order to collect or otherwise use the electricity generated by the solar cells 14, the solar tile 10 includes electrical terminals 28 and 30. Terminals 28 and 30 are electrically coupled to electrical contacts 32 and 34 of solar tile 14 by respective conductors or busbars 36 and 38. Each terminal 28 and 30 takes the form of a round terminal surrounding a respective hole 40 and 42 formed in the solar cell tile 10. In particular, each hole 40 and 42 is formed in a portion 44 of the carrier tile 12 that does not include the recess 20.

  Busbars 36 and 38 are electrically coupled to their respective terminals 28 and 30 by any suitable method such as soldering. During the manufacture of solar tile 10, terminals 28 and 30 and bus bars 36 and 38 can be attached to solar cell 14. When the recess or groove 20 is formed in the carrier tile and the solar battery cell 14 is installed in the recess 20, the terminals and bus bars are installed. Thereafter, the cover plate 16 is placed on the solar battery cell 14 and hermetically attached to the carrier tile 12. Thus, the terminals 28 and 30 and the bus bars 36 and 38 are embedded in the solar cell tile by being sandwiched between the cover plate 16 and the carrier tile 12.

  2a-2c show a second embodiment of the solar tile shown at 10B, where the same reference numerals are used to indicate the same features. As is apparent from a comparison with FIGS. 1a-1c, the two aspects are very similar, so only the differences in these aspects will be described.

  Basically, the main difference between these aspects is that the cover plate 16 of the solar cell tile 10B is smaller, and in particular, this is the size to be installed in the recess 20. Therefore, the recess 20 is made deeper, and the total thickness of the cover plate 16 and the solar battery cell 14 is approximately equal to the thickness of the recess 20. Thus, the solar tile 10B will maintain the flat top surface 24 described above in connection with the solar tile 10B. Also, because the cover plate 16 is installed in the recess 20, a curved slope of the bottom edge 26 of the tile 10 </ b> B is provided to the carrier tile 12. Terminals 28 and 30 and busbars 36 and 38 can be embedded in solar tile 10B by being embedded in carrier tile 12, and more specifically by being molded into carrier tile 12.

  For example, a portion of the length of terminals 28 and 30 and busbars 36 and 38 attached thereto can be molded into carrier tile 12 during formation of carrier tile 12. However, the far end of each bus bar extends into the recess 20 and can be freely connected to the solar battery cell 14. The cover plate 16 may also be made from a transparent plastic material.

  The operation and use of both aspects of solar tiles 10 and 10B are the same. For simplicity, their operation and use will be described below with reference to tile 10 only.

  FIG. 3 shows an array of solar tiles 10 coupled to and overlying a roof structure 46 that includes a plurality of parallel roof rafters 48. As will be described in more detail below, the solar cell tile 10 is connected to an underlying base tile 100, which is further secured to an underlying rafter 48. Solar cell tiles 10 are arranged in successive rows 52a-52i, where row 52a is the lowest. Consecutive rows are offset by half the width of the solar tile 10 with respect to the bottom row. In addition, the higher row partially overlaps the adjacent lower row. For example, the solar cell tiles 10 in the column 52b overlap the solar cell tiles 10 in the column 52a. In particular, the higher row solar tiles 10 overlap a portion 44 of the lower row solar tiles 10. This arrangement of solar tiles 10 provides a roofing structure 46 with a roofing material having a slate or shingled geometric appearance. This appearance is highlighted by the slate-like appearance and color of the solar cell tile 10.

  In the simplest form, the opposing longitudinal sides of the solar tile 10 are flat and touch the side of the adjacent tile 10. If a waterproof seal is required, a bead of sealant material is required between or on adjacent surfaces. However, in an alternative embodiment, as shown in FIGS. 4 and 5, the opposing longitudinal sides 54 and 56 of each solar tile 10 can be formed of a sealing structure or sealing element that, when fitted together, A waterproof seal is formed between adjacent solar tiles 10 in any particular row 52. That is, the side 56 of the solar cell tile 10 can be mated with the longitudinal side 54 of the adjacent solar cell tile 10 to form a seal. This can be achieved in several different ways. For example, FIG. 4 shows a cross-section of tile 10 through portion 44, where side surface 54 is formed with a longitudinal groove 55, and side surface 56 is longitudinal and transverse to fit into the groove and form a seal therewith. It is formed with a ridge 57 extending in the direction. In the alternative arrangement shown in FIG. 5, the side surface 54 is formed with a laterally extending lip 59 that is half the thickness of the solar tile 10, while the side surface 56 is thick. Is also half of the solar tile 10 but with a complementary lip 61 that is flush with the bottom surface of the carrier tile 12 so that the side 56 of one solar tile 10 is adjacent to the adjacent solar tile. A waterproof seal can be formed by overlapping the 10 side surfaces 54. The sealing effect of both arrangements is that of one or more rubber seals 63 acting between the tongue 57 and the groove 55 in the first example and between the overlapping lips 61, 59 in the second example. By providing, it can be enhanced.

  6a, 6b, 7 and 8 show in more detail aspects of a base tile assembly 100 to which one or more solar tiles 10 can be connected. Base tile 100 includes a substrate 102 having a first (top) surface 104 and an electrical connection system 200 supported by substrate 102. The electrical connection system 200 includes one or more posts 204 having a plurality of conductive rails 202 extending from side to side on the substrate 102 and free ends 206 each extending above the first surface 104.

In the particular embodiment shown in FIGS. 6 a, 6 b, 7 and 8, the substrate 102 includes a bottom shell 110 having a flat bottom surface 112 and a peripheral wall 114 extending around the bottom surface 112. A gap 116 is defined between the bottom surface 112 and the peripheral wall 114. The conductive rail 202 is installed in the gap 116.
The substrate 102 also includes a top shell 120 that overlies the air gap 116 and is hermetically attached to the bottom shell 110. Top shell 120 is provided with a row of holes 122 through which the free ends of posts 204 extend. Prior to sealingly attaching the top shell 120 to the bottom shell 110, the void 116 may be filled with an insulating material to minimize heat passing through the base tile 100.

  A complementary connector is formed at the opposite end of the rail 202 so that one end connector of the rail 202 of one base tile 100 is electrically connected to the electrical connector of the other rail 202 of the adjacent base tile 100. Can be connected. That is, the rails 202 of the horizontally adjacent base tiles 100 are connected together to provide electrical continuity between the horizontally adjacent tiles 100. As shown in the circuit diagram of FIG. 6b, this aspect of the electrical connection system 200 provides each base tile 100 with three independent banks of parallel connected solar tiles 10. FIG. Each bank is electrically connected to an adjacent bank of an adjacent base tile 100. However, as described below, different electrical connection systems can be incorporated into the base tile to provide electrical output.

Further details of the structure and other characteristics of the base tile assembly 100 and electrical connection system 200 are described in the applicant's co-pending patents. The above brief description is provided to assist in the following description of the operation and connection of solar tile 10.
As previously described, each solar tile 10 is provided with a pair of terminals 28 and 30. A plurality of solar cell tiles 10 can be connected to the base tile 100. This is accomplished by aligning the terminals 28 and 30 of the solar tile 10 with the free ends 206 of the two side-by-side posts 204 that extend above the surface 104. For example, referring to FIG. 8, to join the first solar tile 10 to the base tile 100, the lower left corner free ends 206 a and 206 b of the base tile assembly 100 are connected to the holes 40 and 42 of the solar tile 10. Extrude through. The posts 204 are configured to make electrical connections with corresponding terminals 28 and 30 and provide electrical coupling with the solar cells 14 of this particular solar tile 10. Subsequently, adjacent solar tiles 10 in the same row as before are joined with the next two side-by-side free ends 206. If this process is continued for each row of solar tiles 10, the entire roof structure or a portion thereof can be covered with solar tiles 10.

The electricity generated by the solar cells 14 of each solar tile 10 is conducted through the posts 108 and rails 106 to remote electrical devices and equipment, such as batteries, inverters, heaters or other equipment.
FIG. 1 shows a solar tile 10 having 18 solar cells 14 arranged in a 3 × 6 matrix. 3 and 6 show a base tile 100 to which nine solar tiles 10 can be connected.

The specific number of cells 14 per solar tile 10, and the manner in which the cells are connected within the tile 10, and the number of tiles 10 connected to each base tile 100 and the manner in which the tiles 10 are electrically connected Depends on a number of design considerations. These include, but are not limited to:
(A) the nature of the load driven by the solar tile 10, in particular any minimum voltage and / or current requirements;
(B) the shape and structure of the manufactured solar cell 14 and how the cell is spread over the carrier tile 12; and (c) the shielding effect on the cell 14.

For example, if the solar tile 10 according to this aspect of the present invention is used to provide a voltage sufficient to drive a typical indoor grid inverter, the cell 14 will generate a maximum voltage on the order of 180V. It is appropriate to combine them in various ways. For example, suppose a typical readily available polycrystalline solar cell produces a maximum voltage of about 0.5V. The current generated depends on the cell size and area. Obviously, a large number of cells 14 need to be connected in series to generate 180V. To determine the optimal method for generating a voltage of about 180V, it is necessary to consider a trade-off between:
(I) the series-connected solar cells have a large area, which means that one of the series-connected cells has a shielding effect (ie opaque by surrounding buildings or such as leaves and / or bird droppings) If not completely irradiated due to foreign material), may result in reduced power output;
(Ii) the solar cells connected in series have a small area, which is less susceptible to shielding effects, but raises safety concerns to generate higher voltages, and the necessary load and / or Or it may generate a current that is not high enough for the associated energy management system.

  One particular structure, as shown in FIGS. 6c and 6d, appears to be suitable for driving a typical indoor grid inverter with MPPT range 150 + V, which is arranged in a 3 × 3 series connected matrix. Each tile 10 having an array of nine solar cells 14, where each base tile 100 holds nine series-connected solar tiles 10. The electrical connection system here differs from that shown in FIGS. 6a, 6b and 7 because it provides a series connection between each solar tile 10 as shown in FIGS. 6c and 6d. . In such a structure, each base tile 100 produces an output voltage of about 41V and a current of about 1.25A. By connecting five base tiles 100 in series together, an output voltage of about 180V is achieved. When each base tile has a dimension of 600 × 600 mm, the area of the roof required to generate about 180 V is 600 × 3000 mm, and five base tiles 100 are arranged side by side.

  However, this is not the only possible structure for generating a voltage sufficient to drive the intended inverter. Other structures are possible, for example, each solar tile 10 has 10 series connected solar cells 14 arranged in a 2 × 5 matrix, where the base tile 100 is 9 series connected. It has a tile 10. In this case, each tile 10 produces about 5V, so each base tile 100 produces about 45V, and in this case four series connected base tiles 100 are required to produce about 180V.

  In a further alternative, each solar tile 10 may have 25 solar cells 14 arranged in a 5 × 5 matrix, for example. In this case, each tile 10 produces about 12.7V, so each base tile 100 with nine series connected solar tiles 10 produces about 114V, in this case to achieve an output of 180V. Two series connected base tiles 100 are required.

In the above structure, each solar tile 10 includes a plurality of solar cells 14. This requires cell disconnection and hence disposal.
In a further variation, each solar tile may include one uncut solar cell. By having a parallel connection between the solar tiles on each base tile, but shown in series, as shown in FIGS. 6a and 6b, each base tile has an output voltage of about 4.6V and about 5 Generate a current of 1A. Therefore, 40 series connected base tiles are required to achieve an output voltage of at least 180V. However, using electrical connections as shown in FIGS. 6c and 6d, each base tile produces an output voltage of about 0.5V and a current of about 5.1A. Thus, to achieve an output voltage of at least 180V, 119 series connected base tiles are required.

  Having described aspects of the present invention in detail, it will be apparent to those skilled in the art that many modifications and variations can be made without departing from the basic inventive concept.

  For example, the carrier tile 12 is described and shown as including one recess 20 for installing one solar cell 14. However, you may form many recessed parts in which a separate small photovoltaic cell is installed in each. Further, terminals 28 and 30 are shown as separated through-hole terminals on carrier tile 12. However, in another form, terminals 28 and 30 may be formed concentrically with each other so that an electrical connection can be achieved using a coaxial single pin connector. Conversely, if desired, more than two terminals may be provided to the tile 10, for example providing two positive terminals and two negative terminals, where the same polarity terminals are connected to the solar cell. 14 in parallel. This provides a certain redundancy in case one connector fails and provides a stronger mechanical coupling of the solar tile 10 to the base tile 100.

  All such modifications and variations are considered to be within the scope of the invention, along with others that will be apparent to those skilled in the art, wherein the characteristics of the invention are determined from the foregoing description and the appended claims.

Claims (27)

A solar cell tile,
A carrier tile having a first side provided with a recess;
One or more solar cells installed in the recess; and a cover plate overlying the solar cells and hermetically attached to the carrier tile;
The solar cell tile comprising:   The solar cell tile of claim 1, wherein the carrier tile is made of a plastic material.   The solar cell tile according to claim 1 or 2, wherein the carrier tile is formed by a molding method.   The solar cell tile according to any one of claims 1 to 3, wherein the solar cell tile has a slate-like appearance when viewed from a side where the solar cell is provided.   The solar cell tile according to any of claims 1 to 4, wherein the carrier tile is of a slate-like color.   6. The solar cell of any of claims 1-5, wherein the solar cell is of a slate-like color, or alternatively it is substantially transparent so that the underlying carrier tile can be seen through the solar cell. Solar cell tile as described in.   The solar cell tile according to claim 1, wherein at least one edge of the solar cell tile has a curved or rounded outline.   The solar cell tile according to any one of claims 1 to 7, further comprising one or more electric terminals, wherein electricity generated by the solar cells can flow to the electric device far away through the electric terminals. .   9. The solar cell tile of claim 8, wherein the carrier tile is perforated and contains a fastener for holding or securing the solar cell tile assembly to a desired location or position or support.   The solar cell tile of claim 9, wherein each electrical terminal is located adjacent to a hole.   The solar cell tile according to claim 9 or 10, wherein each electrical terminal circumscribes a respective hole.   The solar cell tile according to any one of claims 8 to 11, wherein each electric terminal has a shape of a ring made of a conductive material.   The photovoltaic tile according to any of claims 8 to 12, wherein a conductor is provided to establish an electrical connection between each electrical terminal and the photovoltaic cell.   The solar cell tile of claim 13, wherein each conductor is in the form of a bus bar.   The solar cell tile according to any one of claims 8 to 14, wherein the electric terminal is embedded in the solar cell tile.   The solar cell tile according to claim 13, wherein the conductor is embedded in the solar cell tile.   The solar cell tile according to any one of claims 1 to 16, wherein the cover plate is installed in the recess.   The solar cell tile of claim 17, wherein the combined thickness of the solar cell and cover plate is substantially equal to the depth of the recess.   The solar cell tile according to any of claims 1 to 18, wherein the surface of the solar cell tile with the cover plate is substantially flat.   17. A solar cell tile according to any one of the preceding claims, wherein a cover plate overlies and has a common termination substantially with the carrier tile.   21. The solar cell tile of claim 20, wherein the solar cell has a thickness that is substantially less than or equal to the depth of the recess.   22. A solar cell tile according to claim 20 or 21, wherein the electrical terminals are sandwiched between the carrier tile and the cover plate. A carrier tile with at least one through-hole electrical terminal;
One or more solar cells supported on a carrier tile; and a conductor for each electrical terminal;
The or each conductor provides an electrical connection between a respective electrical terminal and the solar cell; and at least a portion of the electrical terminal and the conductor is a solar tile. Embedded in the solar cell tile.   24. A solar cell tile according to claim 23, wherein the solar cell tile has a slate-like appearance when viewed from the side supporting the solar cell.   The solar cell tile according to claim 23 or 24, wherein the carrier tile is provided with a recess for supporting the solar cell.   26. The solar tile of claim 25, further comprising a cover plate overlying the solar cell and sealingly attached to the carrier tile.   27. A solar cell tile according to any of claims 13-15, 25 and 26, wherein the distal end of each conductor is a free end and extends into the recess.

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